Commutator and method of making the same



2 Sheets-Sheet 1 GILBERTPZ Z' J E ROBERT 11/. MESH ROBERTJ Pit/1s 3% Sept. 3, 1963 G. P. ICKES ETAL COMMUTATOR AND METHOD OF MAKING THE SAME Filed Sept. 6, 1960 Sept. 3, 1963 e. P. ICKES ETAL COMMUTATOR AND METHOD OF MAKING THE SAME 2 Sheets-Sheet 2 Filed Sept. 6, 1960 H r S 5, mfii WW 4 1 W J T E W; F 5 M00 GR44 W Z 4;

E v 0 7 1E WT S Inc., Amherst, Ohio, a corporation of Ohio I bration. t I t A general objective is 'that the finished, commutator r 3,102,965 i 'COMMUTATQR ANDY'METHOD or MAKING THE SAME :Gilbrt P. Ickes, Robert W. Marsh, Robert 'L Plas,

Elyria, Ohio, assignors to Amherst Metal Products,

" Filed Sept. 6, 1960,'Ser'.JNo. 54,168

Y 2 Claims, (31. 310-435 "This invention relates to commutators and impnoved steps comprising a method of making the same;

'Ihe commutator with which this invention is particularly concerned 'comprises a met-allic hub adaptedto be mounted on a shaft and a plurality of bars parallel to the axis and a supporting means in thenature of molded insulating material which serves essential functions, namely, maintaining the respective positions of the components and anchoring of the commutator bars,'and also acting as effective electrical insulating material between the segments forming the commutator bars. 7

An object of the invention is to provide a novel and efli'ective mechanical anchoring of the individual commutatorbars which shall be consistent with the forming of a cylindrical member which is later out between the anchoring members to form the 'circumferentially separated commutator bars. t

v General objects ofthe invention include providing the L finished commutator which will Withstand much higher rotational speeds in pnoportion'to its diameter than prior commutators of this general nature in which the anchoring of the individual commutator bars depends only upon the strength of the molded insulating material, Our novel construction provides rigid mechanical metal elements in radially overlapping spaced'relation, whereby a portion of the moldedi-nsulating material between the hub and bars is in direct compression, while material under compression is prevented from any tendency to flow 13161? ally.

More specific objects include the formation of the metal parts suchjthat opposed shoulder surfaces may be positioned to overlap longitudinally, that is, transversely of radial lines for such effective anchoring, while permitting convenient assembly and enabling the carrying out of simple molding operation.- I

'Another specific'object is to provide additional anchoring connections'within the area of each commutator bar which may coact with the molded insulating material and aid in preventing any loosening resulting in minute viassemblywith its separated commutator barsmay mainrain a-high degree of circumferential accuracy. Oommutators according to our invention maybe made in various sizes and meet exacting requirements; Commutators of an inchand a quarter in'diameter, for example,

made according to the present invention, have been subjected t-o notational speeds cf'thirty to forty thousand r.p.m. or more, and when the temperature of the parts rose to 400 F. or 200 C. Correspondingly seve'retests have to be met in maintaining accuracy and" uniformity of spacing to resist, when in use, 225 volts direct current, huawn resist from bar to bar, and from the bars to the as high as'Zl 00 volts, 6O cycle A.C.

Other objects of the invention include the shaping of a blank to be formed into, thecylinder from which the commutator bars are to be cut and which blankmay be shaped to pnovide the anchoring elements, spaced according to the number of commutator bars required, and which may also have means for circumferentially locating the first and remaining indexed saw cuts separating the I of the retaining flange 6 or 7. It is then curved abruptly i FIG; 12 shows a mold numerals and characters, a metallic cylinder in predetermined segments formingthe comma: t-ato'r bars v i c so construct the huband end I A further object is to c I portions rigid therewith'as to readily coact with comparatively simple ,die membersv to permitrnolding of the insulating, and supporting material 'undervery high presuniformity and without distortion of sure with complete any of the" parts.

Other-general objects are to sofform the huh retaining elements and co-acting anchor-s. as to permitrapid high production with uniform accuracy and economical manufacture and assembly. 7 r V Other specific advantages and novel. characteristicspwil l lates to the'accomp a'nyifigdrawings;. In the drawings:

become apparent in the "following description which re- FIG. 1 is an end elevationl f the finished commutator;

. FIG, 2 is a side elevation of the same;

' 7 FIG; 3,-is, an axial cross-section on aiscrn ewhar em larged scale; I q FIG. 4 is a perspective view of a portionof the blank pm which the commutator. bars and their anchoring elementsare formed; i

' FIG-5 is a fragmentary'portion of this blanklwiththe thin side portions cut to form the extensions ion the am choring elements;

FIGS. 6 and 7 are details choring elements cylinder} a I 7, FIG. 8 is a perspective of a completed cylinder with showing the strip and prior 1 to forming the blank-into the the anchoring elements at each end;

.' FIG; 9 is a composite of a group of the elements and anchoring retainingv embers and the side elevation or the completed cylinder; :v ,7

, 'FIGL "l0 is an enlarged "diagrammatic sectional view illustratingtheposition of theanchoring elements and the portion .of a molded retaining and insulating material sub jected to direct compression under centrifugal force;

FIG. ltl isa detail view on the same scale, showing the incidental anchoring depressions formed ineach commut-ator bar, and I a I 1 i t particularly adapted for holding the parts in their proper relation while the insulating molded material is forccd'therein. p

Except for FIGS. 3, l0, and 11', the views show the parts on the same scale, which,'however,is larger'than i the so called small commutators, although commutators of comparable size or larger may be made by the method ofthepresent invention. v p

Referring to the drawings by theuse of reference hub .1 is shown "as having a cylindrical bore and may have a knurled exterior 2 (FIG. 9 Supporting and retaining flanges 3 and ,.4

are suitably secured in substantially radial positionsand heldby out-turned portions 5 ofthe hub formed by spin ning of swedging. These flanges may besecured by brazing or welding. Eachof themembers 3 and 4 has an out- ,wardly olfset radial portion and an inturned short cylindrical flange portion as at G and 7, respectively.

Each of the cornmutator bars has an anchoring element, integral with each end thereof, slightly-narrower than the circumferential Width of the commutator. bar, and formed, as shown particularly in FIGS. 7 and '10,

t somewhat in the nature of: the letter 8 each having a t portion 10 extending'longitudinally parallellwith the axis beneath the flange 6 at one end and a similar pontion'correspondingly extending'beneath and parallel with the overhanging flange 7, and each anchor element has'a radially extending portion as at 12, in the finished commutator positioned to be spaced from the adjacent edge Patented Sept, 3, 1963 tor bars later cut from the mid-portion 25. I

These" side wings 26 are now slotted to form spaced and turned backwardly'upon itself as at 13,.remaining integrally connected with the commutator bar proper 15.

r In the finished commutator, the molded insulating material M holds the commutator bars and end retaining 'subjectedto the centrifugal force acting upon each cornniutator bar, and'this portion of the plastic material, subject to resulting compression, is indicated in the dotted line rectanglesat M and M? in FIG. 10. Likewise, these compressed portions of the insulating and supporting ma- 'terialareshownfparticularly in the upper portion of "FIG. 3.

We recognize, that commutator bars have been formed of a hollow cylinder of metal havinglprojections which -may engage molded'coresupports. Further, it is well known to separate such a cylinder "into the desired number-of segments, each having anchoring, fingers or projections, by sawing or cutting after filling the cylin- "der with molded supporting material. However, the commercial demands and requirements for higher'speeds in proportionto given diameters render such previously used anchoring means inadequate. The molded plastic mate- 7 rial forming the coreand supporting and anchoring the commutator bars is not ofitself strong enough to hold the bars when subjected to these greatly increased rota- I tional' speeds. Prior anchoring elements or fingers have beenturned inwardly at an angle and embedded in the supporting material, but only a small portion of the plastic itself is efiective as an anchor, and its inherent tensile strength and breakingstrength is inadequate.

' It becomes apparent, therefore, that utilizing suitable plasticmaterial having at least as much strength in all plysical properties,fias well as insulating characteristics vas the material heretofore used; and so arranging the parts that it retains and confines a solid portion of this material between "longitudinally extending overlapping and insulatingly spaced shoulders constitutes a very important improvement.

. Such insulating and'supporting material is substantially 1 incompressible, and when a portion of it is so confined between spaced apart rigid metallic elements as to be subjected primarily to compression only, the resistance to centrifugal force acting upon the commutator bars is so greatly increased that much higher rotational speeds and correspondingly continued maintenance of accuracy and cylindrical uniformity of the commutator may be attained.

By the construction of the parts, as above described, we are enabled to manufacture such a commutator efficiently and economically, and with desired accuracy,

by a series of steps which constitutea novel method of making such a cdmrnutaton The'blank from which the cylinder is formed is or course made of. suitable electrically conductive metal,

such as copper or special alumin um alloy,

or other metal ofsulficient rigidity and conductivity.

A strip isformed by rolling or'other suitable processing -to provide a mid-section 25'- and laterally extending'parallel wing portions of reduced thickness,corresponding to that required for the S-shaped anchoring members.

- Asappears in FIGS. 4 to 7, the mid-portion 25', of the strip constitutes a longitudinal band of uniformywidth corresponding to thedesired length of the commutator bars the-thinner lateralportions 26 extending each wayv from the thicker hand. 'These thinner side portions are preferably'about one-half the thickness of the commutafingers, as" shown at 28 integral with the strip 25 and of the desired width for the individual anchoring elements of the commutator bars. The strip'with its laterally prothese depressions will be further described hereinafter;

jecting" separatedintegralfingers is now subjected to a at 10, for a short distance substantiallyparallel with the body of thestrip. The tips of the portions 10 stand in arow substantially evenly with the widthof the strip, as appears in F161 7, or projecting slightly beyond the w1dth' of the strip, as appears particularly in FIG."10

' The shape and dimensional proportions of the anchoring fingers may be varied to vsuit the conditions desired, both in the requirements of formation, as-"well. as in the attaining of the most effective-anchorage in the finished anmature. j

The incidental additional anchorage, above'mentioned,

may be provided by'forming depressions in the underside of the body of the strip. As shown, shallow round cylindrical depressions 30 are formed inalignment with V opposite pairs of fingers and in what'willbecome the underside of each commutator bar. The function of The strip is now cut to a length equivalent -to the circumference of the commutator andis formedlinto an accurate cylinden'as shown in FIG. 8. The cylindrical hub elementl is then assembled, first permanently affixing one end disk" 3 to the receiving. shoulder, as previously described. The hub with one disk attached is then inserted intothe commutator cylinder, and the end disk 4 lS then applied to the hub and similarly permanently secured, as by another small end flange 5.

The end disks are thus positioned with their inturned flanges surrounding the hooked ends 10 of the anchoring fingers. These parts are then positioned in a suitable die which accurately concentrically positions the components while maintaining ,the endwise positioning of the flanges 6 and 7, each separated from the adjacent circular row of anchoring fingersj 7 Referring to FIG. 12, a specially constructed die is illustrated where a central shaft or core pin 40 rises from an enlarged portion 41 forming a shoulder and a portion of the bottom wall of the die cavity in a die' member 45. I his die member has a bottom wall surface, 'as shown, andwhich curves upwardly slightly to an annular shoulder 46 at the lower portion of the cylindrical surface of the cavity, which is adapted to closely fit the outer surface of the armature cylinder. The shoulder 46 against which one end of the hub and one end disk may rest, is so positioned as to assure the correct spacing between the inturned flange of the end disk res-ting on the bottom and the adjacent row of S- shaped or hooked anchoring fingers.

The cylindrical surface of the die cavity is of a height corresponding to the width of the strip'of the midportion 25, and it will be seen that the opposite end disk likewise has its flange properly spaced, from the adjacent hooked anchoring fingers.

A closing and sprue containing die. member an annular inwardly extending shoulder 51, correspondtapers upwardly and inwardly to the passage-for the moldedmaterial, as indicated at 54. The upper end of the'corepin 40 is preferably tapered, as shown, and the surface of the flaring sprue opening is spaced to provide upper end disk. With' the die parts firmly held in the clearance (for permitting flow of the material around the positionshown and accurately positioning thencommutator components, the anchoring insulating mounting material in plastic condition is forced into andfills the cavity.

5 0 has i flanges substantially simultaneously. In practice, a very short time only is needed to sufficiently set thematerial to remove the. molded article in its assembled (form. The sprueportion of the plastic is then trimmed from the adjacent disk and hub. I

The unitary commutator body is now complete except for cutting the cylindrical strip 25 into the separate commutator bars. slitting through the cylindrical portion, while properly indexing, that is, turning the precise amount after each out according to the desired number of commutator bars, and, of course, corresponding to a number of anchoring fingers at each end of thelcornmutator, whereby the anchoring fingers remain undisturbed and integral with their respective bars.

The position for the first slot or cut must, of course, be precisely determined, and inasmuch as the anchoring fingers may be substantially entirely enclosed and hidden by the molded insulating and mounting material, a novel means is employed for locating the first separating This is accomplished by longitudinal longitudinal cut at the beginning of the series of subsequent indexed cuts to form the commutator bars. The manner of positioning the starting out is important for the reason that removing orevenslightly defacing any part of the molded material to locate an anchoring fingerwould weaken or destroy the insulating effect at such a oint. A minute space between the meeting ends of the cylinder formed by the strip 25 may permit electronic detection and location for the first cut. Small projections 27 at one end of the strip 25 may be used for this purpose.

Mechanical positioning for starting indexing may be accomplished by forming an indentation in the strip 25 at a predetermined circumferential position with rela tion to a pair of anchoring fingers. Such an indentation may constitute a longitudinal groove or depression 69 in FlG. 8 terminating a substantial distance from each edge of the strip 25 of the cylinder. depression would need to Ibe'only one or two thousandths of an inch in depth to he engaged by a locating instrument, and preferably would be so located as to be cut away with the slit between adjacent commutator bars. The terminating of the ends of such a groove short oat the sides of the cylinder is to avoid filling with molding material during the molding operation.

A reciprocating thin circular saw may be used for slotting and indexing, and this operation may be automatic and very rapid in forming the separate commutator bars.

Conventional receiving slots, not shown, for connect-. ing the terminals of the wires of the armature coils to the commutator bars are preferably cut later in the otherwise finished cornmutators.

When commutator bars are subjected to the relatively high centrifugal force, there occurs a tendency to yield or spring a minute amount which may permit minute vibration, resulting in loosening them. Relative differential of thermo-expansion and contraction between the molded insulating body material and the metal is also a iiactor to be considered, and, accordingly, we may provide the incidental anchorage referred to in connection with the depressions 30, two of which are shown as formed to become positioned on the underside of each commutator bar.

When the depressions 30 are formed, the shallow sides are cylindrical. When the flat bar portion 25, however, is convoluted to form the cylinder, as described, a minute dovetail eifect results from the curving of the mid-strip 25, as indicated diagrammatically by the lines 30a in Such a longitudinal FIG. 11 where the opposite become minutely convergent as are shown by these approximately radial lines 30a. These depressions receiving the molded material alford an additional anchorage against longitudinal loosening of the bars and are helpful in avoiding the loosening resulting from the. relative differential of thermo-expansion and contraction between the molded body material and the metal.

From the foregoing description it will beseen that we have provided a commutator construction 'il'l'WhiCh molded insulating material is confined and encased, and

that the components form, in effect, an annular spool-' like container for the core of molded compound;

molded compound may be of thermo=setting or thermoplastic material of substantial density and rigidity and preferably of low coefficient of expansion for material of this character. It should have high compressive (nonyielding) strength when set, and be resistant to cold flow. Thus, when encased and confined against flow, the molded insulating material maymost effectively retain the interposed portions at M and M between the anchoring fingers 10 and the flanges 6 and 7, so that these inter-.

posed portions may most effectively resist the compressive action of the tendency of centrifugal force to move the commutators radially outwardly.

As indicated, the finished commutator thus comprises essentially a short cylinder of the usual shape having great rigidity and durability, and, as indicated, capable of withstanding the temperature, to which it may be subjected in use, of as high as 400 F. "The insulating characteristic of the material being high, the spacing of the cornmutators may be determined according to 'standard practice, while meeting a bar to bar test for eifective insulation against 225 volts DC, for example.

Illustrative sizes of commutator, according to the present invention, may be one and a quarter inches in diameter or less; the commutator bars may be substantially eighty-thousandths of an inch in radial thickness, while the anchor portions are substantially one-half that thickness. There may be, for example, from fourteen to thirty-two commutator bars, which by ourconstruction will maintain their longitudinal parallel and individually straight conditions and will not become loose nor likely to rattle even when subjected to most severe operating conditions.

In the slitting or cutting of the commutator bars from the mid-strip of the cylinder, the saw cuts inwardly beyond the thickness of the bars slightly, but insuflicient- 1y to weaken the solid body of the molded insulating material. The approximate proportionof the slots between the commutator bars is indicated in FIG. 11, and

the cut into the material is there indicated in broken lines at S The method described is capable of being performed with great rapidity and economy. .The formation of the bar of FIG. 4 and the fingers of FIGS-5, 6, and 7 lending themselves to treatment by rolling and die-cutting with great rapidity; formation of the cylinder of FIG. 8 with accuracy; the positioning of the parts in the die constructed according to FIG. '12, according to the descriptron pertaining thereto, are all steps which may be practiced with uniformity and efficiency.

The assembly of the parts prior to inserting them in the die which positions them during molding is obviously simplified over that required for previous constructions. The slotting out the cylindrical band to form-the individual commutator bars 1'5, each with its anchoring fingers after the molding, requires only that the first slot be accurately located for subsequent indexing according to the required number of commutator bars. In practice, the indexing and reciprocation oi the cutter during this slotting action may be accomplished for a complete commutator in a matter of seconds.

Itis desirable to avoid, Where practical, increasing sides of these depressions nents' of the assembled commutator, all contribute to' assurance of maintaining the relationship ofthe parts duringsuchoperations and subsequent handling, as well as later in use. v i v Obviously, any oxidation on the outer surfaces of the commutator bars may be readily removed without d e-'- stroying the cylindrical accuracy of the finished commutator; and? the usual receiving slots for the armature wire terminals, as stated, are preferably cut or formedshortly beforeattaching the terminals on the finished 'armature,-thus avoiding intermediate oxidation within the receiving slots.

6 Various modifioations in size and proportion and changes in the mechanical details may be made Without departing from the spirit of the present invention as defined in the appended claims.

- Having thus described our invention, what we claim is: J J1. A. method of'making commntators which comprises In this anchoring fingers to project at right angles from the midportion and then laterally to provide anchoring ends on said fingers, providinga rigid 'hub portion, affixing a radial disk to one end thereof having a short cylindrical flange" turned toward the hub, convoluting said mid-portion into a cylinder with meeting ends, and placing the hubpor-" tion Within the cylinder and fingers, affixing a corresponding disk with a cylindrical flange turned toward the hub,

placing the assembled hub with its disks and the cylinder withits fingers in "a die while holding the flanges and hub concentrically and spaced from the anchoring fingers, filling the cylinder and space between'the flanges with molded insulatingmaterial, removing the unitary strucrture thus formed, locating a saw cut position between aligned anchoring fingers and indexing and cutting the cylindrical portion to form the predetermined number of spaced commutator bars, each having its anchoring fingers with projecting ends spaced from and engaging insulating material within the flanges.

v 2. The method defined in claim 1 in which depressions are formed in the mid-strip in alignment with the anchorforming an el'ongated'metal strip having a thickened midportion with parallel'marginal shoulders and integral side 'Wing portions, the mid-portion being of a thickness corresponding to that of'conimutator bars and the wing portions being of substantially less thickness, slitting the side portions to '-form separated transversely aligned projections, and then bending said'projections inwardly at each side 10f the mid-portion, shaping said projections to form ing fingers and on the side to become the inner side of each commutator bar.

References Cited in the file of this patent UNITED STATES PATENTS 1,362,663 Zimmerman Dec. 21, 1 920 2,846,602 Collins Aug. 5, 1958 FOREIGN PATENTS 558,360' Italy Aug. 22, 1956 874.619 I Germany Apr. 27, 1953 

1. A METHOD OF MAKING COMMUTATORS WHICH COMPRISES FORMING AN ELONGATED METAL STRIP HAVING A THICKENED MIDPORTION WITH PARALLEL MARGINAL SHOULDERS AND INTEGRAL SIDE WING PORTIONS, THE MID-PORTION BEING OF A THICKNESS CORRESPONDING TO THAT OF COMMUTATOR BARS AND THE WING PORTIONS BEING OF SUBSTANTIALLY LESS THICKNESS, SLITTING THE SIDE PORTIONS TO FORM SEPARATED TRANSVERSELY ALIGNED PROJECTIONS, AND THEN BENDING SAID PROJECTIONS INWARDLY AT EACH SIDE OF THE MID-PORTION, SHAPING SAID PROJECTIONS TO FORM ANCHORING FINGERS TO PROJECT AT RIGHT ANGLES FROM THE MIDPORTION AND THEN LATERALLY TO PROVIDE ANCHORING ENDS ON SAID FINGERS, PROVIDING A RIGID HUB PORTION, AFFIXING A RADIAL DISK TO ONE END THEREOF HAVING A SHORT CYLINDRICAL FLANGE TURNED TOWARD THE HUB, CONVOLUTING SAID MID-PORTION INTO A CYLINDER WITH MEETING ENDS, AND PLACING THE HUB POR- 